Thermoplastic injection molding apparatus



Sept. 25, 195 1- Filed Dec. '7, 1948 L. KARDORFF THERMOPLASTIC INJECTION MOLDING APPARATUS 12 Sheets-Sheet 5 Misc J55 56 30 J62 J JWA' IN VEN TOR. Lao/v KARDORFF ATTORNEY Sept. 25, 1951 L, KARDQRFF 2,569,174

THERMOPLASTIC INJECTION MOLDING APPARATUS Filed Dec '7, 1948 v 12 Sheets-Sheet 4 IN V EN TOR.

7 LEO/V KARDOEFF L 1 Q 46X 7 BY 4 1% 452 v ATTORNEY Sept. 25, 1951 KARDORFF 2,569,174

THERMOPLASTIC INJECTION MOLDING APPARATUS Filed Dec. '7, 1948 12 Sheets-Sheet 6 TWC E I N V EN TOR. LEO/V KARDORFF ATTOH/VEY Sept. 25, 1951 1.. KARDORFF THERMOPLASTIC INJECTION MOLDING APPARATUS 12 Sheets-Sheet 7 Filed Dec. '7, 1948 INVENTOR LEO/V MRDORFF A ATTORNEY Sept. 25, 1951 KARDORF'F 2,569,174

THERMOPLASTIC INJECTION MOLDING APPARATUS Filed D80. 7, 1948 12 Sheets-Sheet 8 IN VEN TOR. LEO/V KARDORFF TIC -1 BY ATTORNEY Sept. 25, 1951 KARDORFF 2,569,174

THERMOPLASTIC INJECTION MOLDING APPARATUS Filed Dec. '7, 1948 12 Sheets-Sheet 9 INVENTOR. ZEO/V KARDOHFF BY @gfi w,

fiTTOR/VEY 12 Sheets-Sheet 10 L. KARDORFF THERMOPLASTIC INJECTION MOLDING APPARATUS Sept. 25, 1951 Filed Dec.

NR 6% m J R; INVENTOR.

' LEON KARDoR'FF ATTORNEY Sept. 25, 1951 L. KARDORFF THERMOPLASTIC INJECTION MOLDING APPARATUS 12 Sheets-Sheet 11 Filed Dec. 7, 1948 IN VEN TOR. Z

Sept. 25, 1951 KARDORFF 2,569,174

THERMOPLASTIC INJECTION MOLDING APPARATUS Filed Dec. '7, 1948 l2 Sheets-Sheet 12 BY PM Patented Sept. 25,,

THERMOPLASTIC INJECTION MOLDING APPARATUS Leon Kardorfi, Jackson Heights, N. Y., assignor to Automatic Injection Machines Corp., New York, N. Y., a corporation Application December 7, 1948, Serial No. 63,975

This invention relates to thermo-plastic injection molding apparatus.

It is the primary aim and object of the present invention to provide apparatus of the above type which, while rugged and comparatively simple in construction, may be operated automatically for any length of time during which it will perform efliciently and reliably without requiring human supervision or control other than starting and stopping the apparatus.

It is another important object of the present invention to provide in apparatus of this type automatic controls which to a large extent obviate the rise of certain critical operating conditions of the apparatus that heretofore resulted frequently in inferior or totally unsatisfactory molding.

It is another important object of the present invention to make provisions for automatically stopping the operation of the apparatus if in the course of any operating cycle thereof there will arise, despite the automatic controls, any one of a number of certain operating conditions of the apparatus which, if unchecked, would result in unsatisfactory molding or damage to the apparatus, or both.

It is another important object of the present invention to design the controls of the apparatus so that, for the start of a production run of the latter after prolonged idleness, an operator need merely manipulate certain controls at one brief time interval in order subsequently to cause the apparatus to melt solid plastic and heat it to correct molding temperature, and thereafter automatically perform in repeat-molding cycles, without any further manipulation or supervision by the operator.

It is another important object of the present 18 Claims. 18-30) invention to make provisions in the controls of the apparatus for operating the later in single molding cycles, each in response to momentary manipulation by an operator of certain controls.

It is another important object of the present invention to provide for facile substitution of different molds in the apparatus, and for facile adaptation of the controls of the apparatus to different substituted molds in the latter.

It is another important object of the present invention to make further provisions in the controls of the apparatus for interrupting any operating cycle thereof immediately on momentary manipulation by an operator of a single control, thus affording the possibility of preventing unsatisfactory molding or possible damage to the apparatus for any reason whatsoever,

It is another important object of the present invention to attain maximum efficiency and productivity of the apparatus, by timing the performances of the various operating mechanisms of the apparatus with a view toward attaining operating cycles of minimum duration.

It is another important object of the present invention to provide in the controls of the apparatus timing equipment which not only stops the apparatus automatically during any operating cycle of excessive duration, but also clearly indicates the particular operating mechanism or mechanisms responsible for the excessive duration of the cycle.

It is another important object of the present invention to provide the apparatus with equipment for automatically ejecting the molded product from the apparatus at the end of each molding cycle of the latter.

It is another important object of the present invention to coordinate the controls of the apparatus with the ejection equipment thereof, to the end of making an automatically or manually started repeat-molding cycle of the apparatus contingent upon the actual performance of the last step in the preceding operating cycle thereof, i. e., ejection of the molded product from the apparatus.

It is another important object of the present invention to resort in any operating cycle of the apparatus to fluid under low pressure for quickly closing the mold, and to make the subsequent application of fluid under high pressure, for keeping the mold closed for the actual molding operation as well as for the continuation of the cycle beyond mold closure, contingent upon actual closure of the mold, thereby to prevent closure of the mold with a force that would sooner or later be damaging to the same, as well as to prevent injection of a plastic charge into the mold if the same is not completely and safely closed.

It is another important object of the present invention to make provisions in the controls of the apparatus for permitting an operator to jog the mold, by power and. in any desired steps, into its closed and open positions without causing any other operation of the apparatus, thereby facilitating the task of setting the apparatus up with different molds, for instance.

It is another important object of the present invention to make further provisions in the controls of the apparatus for permitting an operator harmlessly to shoot or eject, by power, from the injection nozzle of the apparatus plastic which is burned or otherwise unsuited for molding.

The above and other objects, features and advantages of the present invention will be more fully understood from the following description considered in connection with the accompanying illustrative drawings.

In the drawings:

Fig. l is a fragmentary perspective view of apparatus embodying the present invention, the apparatus being viewed from the front thereof;

Figs. 2 and 3 are fragmentary perspective views of the same apparatus, viewed from opposite sides, respectively;

Fig. 3A is a fragmentary section through certain plastic-feeding equipment of the apparatus;

Figs. 4 and 5 together are an enlarged longitudinal section through the apparatus, taken substantially on the line 4,5 -4,5 of Fig. 3;

Fig. 4a is a fragmentary section similar to Fig. 4, but showing the mold open;

Fig. 6 is a fragmentary side elevation, partly in section, of certain controls of the apparatus;

Figs. '7 and 8 are views similar to Fig. 6, showing the same controls in difierent positions of operation, however;

Fig. 9 illustrates, in perspective, the disassembled parts of equipment used for the ejection of a molded product from the apparatus;

Figs. 10, 11 and 12 are plan views of the same ejection equipment in different operating positions;

Fig. 13 diagrammatically illustrates the hydraulic operating devices and controls of the present apparatus, and their lines of communi-- cation; and

Figs. 14 and 15 together illustrate diagrammatically the electrical operating devices and controls of the present apparatus. 7

Referring to the drawings, and more particu-- larly to Figs. 1 to 5 thereof, the reference numeral 28 designates a thermo-plastic injection molding apparatus, comprising a base frame 22, a top frame 24, a plurality of posts 26 which are erected on the base frame 22 and support the top frame 24, an upper platen 28 which mounted on the posts '25, and a lower platen 3i} which is guided on the posts 26 for reciprocation to and from the upper platen 2 8. The base frame 22 is preferably a casting having bosses 32 in which the upright posts 25 are mounted as at 34 (Fig. 4). The top frame 24, which may also be a casting, is seated on annular shoulders 40 on the posts 26, respectively, and is firmly secured thereto by nuts 42 which are threaded over the adjacent shanks 44 of these posts (Fig. 5). The upper, fixed platen 28, which is preferably also a casting, has a rib-reinforced hollow skirt 46 that terminates in a mounting flange 48. The lower, movable platen 30 is provided with bushed bores 58 through which the posts 26, respectively, extend with a sliding fit.

Mounted on the flange 48 of the upper platen 28, as by screws 52, for instance (Figs. 2 and 3), is the top mold member 54 which is provided with a central bore 56 for the reception of the reduced shank of a sprue bushing 58 that extends into a locating ring 60 for an injection nozzle 62. The locating ring 60 is secured in any suitable manner to the top surface of the mold member 54, and the injection nozzle 62 is threaded into or otherwise secured to the lower end of an injection cylinder 84 which is firmly suspended from a bracket 66 on the upper platen 28 by means of ring nuts 68 and I0, threadedly received by the upper end of the injection cylinder 64 and firmly drawn against the interposed web ll of the bracket 66 (Fig. 5). The bracket 66 may be mounted on the upper platen 28 by means of studs "I4 and nuts I6, and the injection cylinder 64 is so adjusted in the direction of its axis as to force the rounded end I8 of the injection nozzle 62 into firm engagement with the adjacent, correspondingly rounded end of the sprue bushing 58 (Fig. 4). Axial adjustment of the injection cylinder 64 is accomplished by turning the ring nuts 68, 10 relative to the injection cylinder 54 which is held non-rotatable by being splined to the bracket 66 as at 88 (Fig. 5)

Seated on the top surface of the lower platen 30, and located thereon by leader pins 84, is the bottom mold member 86 (Figs. 4 and 4a). The top mold member 54 is provided in its bottom face with a recess 88 in which is received a stripper plate 98 when the mold 54, B6 is closed (Fig. 4a). On opening the mold, by lowering the bottom mold member 86 in a manner hereinafter described, the stripper plate 88 will descend with the bottom mold member 86 through part of the opening stroke of the latter, i. e., until the stripper plate 90 becomes seated on stop pins 92 which pass through the bottom mold member 86 and are carried by a plate 84 that rests against the head 96 of a spindle 98, threadedly received in a central post I in a mold cylinder I82 (Fig. 4). The elevation of the stripper plate 98 above the completely retracted bottom mold member 86 may be adjusted by turning the spindle 98 in the proper direction, the lower platen 30 being to this end provided with a suitable opening I 04 (Figs. 1 and 2) for ready access to the central cavity I88 into which the headed spindle 98 projects (Fig. 4). The stripper plate 98 is guided into either one of the positions shown in Figs. 4 and 4a by depending pins IIO thereon which are slidably received in bores II2, respectively, in the bottom mold member 85.

The bottom mold member 88 is provided with a conventional sprue puller II4 that may have an enlarged head for its threaded reception in a tapped bore H5 in the bottom mold member. The stripper plate 90 is provided with a central bore II8 for the reception of the cylinder shank I28 of the sprue puller II4 when the mold 54, 86 is closed (Fig. 4a). The top mold member 54 is provided in its recessed bottom face with one or more mold cavities I28 which communicate with the passage I28 in the sprue bushing 58 through relatively shallow runner grooves I30, respectively. Suitably carried by the bottom mold member may be cores I32 for the mold cavities I26, respectively, in the top mold member 54. In the present instance, the mold cavities I26 and respective cores I32 define, in the closed condition of the mold, thimbles t, respectively (Fig. 2). The stripper plate 98 is provided with openings I34 for the reception of the cylindrical shanks I36 of the cores I32, respectively, when the mold 54, 86 is closed. The leader pins 84 enter preferably bushed bores I48 in the top mold member 54 when the. bottom mold member 86 is closed thereagainst, thereby guiding the latter into accurate closing relation with the top mold member 54. Movement of the bottom mold member 86 on the lower platen 38 into its open and closed positions is accomplished by a double-acting mold plunger I42 which is slidable in the previously mentioned mold cylinder I02. The mold cylinder I02 comprises end members I44 and I46, respectively, and a cylindrical shell I48 which forms the side wall of the cylinder. The end member I44 may conveniently be bolted at I50 to the base frame 22 (Fig. 4), and the cylinder'shell I48 may be threadedly received with its top end in the end member I44. The other end member I46 may be threaded over the bottom end of the cylinder. shell I48. The post I00 is mounted on the end member I 46 by a nut I52 which is threadedly received by the reduced shank I54 of-the post I00.

Interposed between the cylinder shell I48 and the end member I46 is a self-sealing packing ring I 56 to prevent the escape of fluid under pressure from the bottom end of the mold cylinder I02. To prevent the escape of fluid under pressure from the top end of the mold cylinder I02, there is interposed between the cylinder shell I48 and the end member I44 a packin ring I60 which is preferably held compressed by a washer I62. The mold plunger I42 comprises a hollow rod I64 through which the post I00 extends with a relatively loose fit. The glands of the mold plunger I42 are formed by packing rings I66 and I68, respectively, which in the present instance are L-shaped in cross section (Figs. 4 and 4a) and flanked by opposite ring members I10 and,

I12. The packing rings I66 and I68 are firmlyclamped to an interposed spacer I1 4 by the ring members I10 and I12, of which the ring member I12 is threaded over the reduced end I18 of the plunger rod I64 to hold the parts I68, I14,

I66 and I10 in firm engagement with eachother and with an annular shoulder I16 on the plunger rod I64. Escape of fluid under pressure from the bottom end of the mold cylinder I02 through whatever gap there may be between the plunger 35,

rod I64 and post I00, is prevented by a packing ring I80 which embraces the post I00 and is firmly clamped to the ring member I 12 by a ring nut I82 that is threaded into the ring member I12. The plunger rod I64 has a reduced top end I84 which is preferably threadedly received in a steel bushing I86 in the lower platen 30.

Slidable into and from the injection cylinder 64 is a double-acting injection plunger I90 (Fig.

5) which is slidable in an operating cylinder I92,

suitably provided in the top frame 24 of the apparatus (Figs. 5 and 13). The injection plunger I90 is in its most retracted or uppermost position completely withdrawn from the bore I94 in the injection cylinder 64- so as to admit into the latter 292 through which the molten plastic charge is 60,

forced by the plunger I90 after it has been heated to proper molding temperature. Heat is applied to the injection cylinder 64 in the vicinity of the. heating chamber I98 therein by preferably several electric heater bands or elements 204 and 206 5 (Figs. 4 and 5).

Plastic charges for successive molding cycles of the apparatus are supplied to the container I96 through a conduit208 (Figs. 3 and 3A) at the discharge end 2I0 of a cylinder 2I2 in which a rotary feed screw 2I4 propels solid plastic material from a supply hopper 2I6 to the discharge end 2 I 0 of the cylinder 2I2. The cylinder 2I2 may suitably be mounted on the top frame 24 bracket 2IB (Fig. 3A). The feed screw 2I4 may be coupled to, and driven by, an electric feed motor 220 (Figs. 3 and 3A) that may suitably be mounted at 222 on a mounting plate 224 on the cylinder 2I2'.

The apparatus so far described operates in the following manner. Assuming that the mold 54, 86 is open (Fig. 4) and that there is a charge of molten plastic at proper molding temperature present in the heating chamber I98 and discharge nozzle 62, fluid under pressure will then be admitted, as hereinafter described in detail, to the bottom end of the mold cylinder I02 in order to cause ascent of the bottom mold member 86 for closing the mold. After an initial part of the closing stroke of the bottom mold member 86, the stripper plate 90 will become seated on the latter and carried thereby toward and into the recess in the top mold member 54 (Fig. 4a) Simultaneously with the admission of fluid under pressure into the bottom end of the mold cylinder I02, fluid under the same pressure is admitted into. the top end of the actuating cylinder I92 (Figs. 5 and 13), resulting in descent of the injection plunger I90. So far, the fluid applied to the cylinders I92 and I02, while under sufficient pressure to close the mold and to lower the injection plunger I to some extent, is under insuflicient pressure to lower the injection plunger into its lowermost position for forcing a plastic charge from the heating chamber I98 and discharge nozzle 62 into the closed mold. It is at this time that fluid under higher pressure is, as hereinafter described in detail, admitted simultaneously into the top and bottom ends of the cylinders I92 and I02, respectively, in order to hold the mold securely closed and to force the injection plunger I90 into its lowermost position (Fig. 5) for the injection of a plastic charge into the mold.

Fluid under the referred higher pressure will be admitted to the top and bottom ends of the cylinders I92 and I02, respectively, for some time, i. e. at least until the injected plastic charge in the mold has sufficiently solidified to permit the safe ejection of the molded product from the mold. The top and bottom ends of the cylinders I82 and I02, respectively, are then permitted to exhaust and fluid under the initially applied low pressure is, as hereinafter described in detail, admitted simultaneously to the bottom and top ends of the same cylinders I92 and I02, respectiveiy, in order to effect the retraction of the injection plunger I98 into its uppermost position and the descent of the bottom mold member I44 into its 5 open position. The molded product p (Fig. 2),

will, during an initial part of the opening stroke of the bottom mold member 86, follow the latter by virtue of the anchorage of the molded product on the sprue puller H4, and the sprue s of the product will then be torn from the remaining 7 plastic in the discharge nozzle 62 substantially at the restricted end 230 of the passage 282 therethrough. When in the continued course of the opening stroke of the bottom mold member 86 the stripper plate 90 comes to rest against the stop pins 92, the sprue puller II4 will be drawn from the sprue of the molded product, and the cores I32 will be retracted from the latter. The molded product then merely lies on, and is not otherwise bound to, the stripper plate 90 during the remaining descent of the bottom mold member 86 into its lowermost position,

For the removal of a molded product p from the mold, there is provided an ejector arm 240 of the apparatus through intermediation of a 75 (Figs. 1,2 and9 to 12) which is freely slidable 1. on a spindle 242 and splinedthereto' as at 244v so as to be turnable therewitl'r. The ejjector arm 240'rests on nut elements; 241' on' the threaded spindle 242 (Figs. 2 and=3);, and is thusadjustablein its position axially of the spindle 242;. Pivoted at 246 on the ejector: arm 248 are: two companion jaws 248 having confronting, preferably serrated edges 256 with whichto grip a moldedproduct p at the sprue 8 thereof in a manner described hereinafter. The jaw 246 ispivotally connected with a bar 252 by a pin 254' which extends through an elongated slot 256 in the ejector arm 240. The bar 252 is guided for linear movement on the bottom side of the ejector arm 240 by pins or studs 258' which extend. through elongated slots 268 in the bar 252. The jaw 248 is normally urged into the closed position shown in Figs. 9 and 10 by means of a tension spring 262 which is anchored with one end on a pin 264-on the; arm 246,.and with the other end on a pin 266 that depends from the jaw 2.48" and extends through an elongated slot 268" in the arm 246'. When the jaw 248" is permitted to, spring-close, the companion jaw 243 is also urged into closed position by the pin 265 which is drawn by the spring 262 against the adjacent edge 218 of the bar 252 and shifts the latter in the direction of the arrow 272 in Fig. 10 until both'jaws 248' are closed.

As previously mentioned, the mold 54, 86 is, by way of example, adapted for molding thimbles t (Fig. 2) of which a number (four in. the present instance) are connected by conventional runners r with the sprue s of the molded. product. In operation, the ejector arm 240 is, in a manner hereinafter described, swung: from the retracted position shown in Figs. 1, 2 and. 10 inwardly of the mold 54, 36 at such time-during the opening stroke of the bottom mold member 8.6 that the jaws 248 will, at the end of the'inward swin of the arm 246, grip the sprues of. the molded product p (Fig. 11) substantially at the time when the stripper plate 98 has come to rest on the stop pins 92, but before the sprue puller. 114* has been retracted from the molded product. Gripping. of the sprue s by the jaws-248 of the ejector arm. is thus assured. After. the: jaws 248' have gripped the sprue s of the moldedproduct, the ejector arm 246 will, as hereinafter. describedmorefully, be swung outwardly when during. continued" descent of the bottom mold member 86the sprue puller 114 and the cores 132 have been retracted from the molded product on the stripper plate 90. Thus, the molded product p, is, at the time of the outward swing of the. ejector arm 248, free.

to move with the jaws 248"from:the stripper plate 90. It will be observed from Figs. 10 and 11 that. the end 2'56 of the bar 252 extends in the closed as well as sprue-gripping positions of the jaws 248.1 beyond the arm 248, and strikes against a stop plate 273 at the end of the outward swing of the arm 246 (Fig. 12). The stopplate 2e'l8 may be secured in any suitable manner to. abracket 286. which may be clamped to, or otherwise mounted= on, one of the. upright posts 261(Fig; 1). Slight, continued outward swinging motion of the. arm. 246 after the bar 252. strikes the stopplate 273 will, through intermediation oflthespins 265 and;

254, result in opening of thejaws 248 beyond;

their gripping position (Fig. .12), releasing there-- by the sprue s of the molded product p and per:- mitting the latter to gravitate into any suitable. receptacle (not shown).

Reference is nowhad to Fig. 13-;which illustrates diagrammatically the hydraulic operating and control devices of. the. apparatusandv 32 their lines. of communication. Thus, there is provided a reservoir 286 that holds a supply of any suitable operating fluid F, such as oil, for instance. Communicating with the fluid supply a in the reservoir 286 are preferably a large-capacity low-pressure pump 288 and a small-capacity high-pressure pump 298. Communicating with the pump 288" through a conduit 292 is a medium-pressure valve 234 which also communicates through conduit 286 with a return or exhaust conduit R that leads into the reservoir 286. Assuming that the low pressure of the fluid previously mentioned for closing the mold 54, 86 be, by way of example, in the neighborhood of pounds per square inch, the spring 298 in the medium-pressure valve may then be cali brated to keep the valve element 306 closed unless the pressure ofthe fluid from the pump 288 exceeds 200 pounds per square inch, for instance. Branching from the conduit 292 is another conduit 382 which leads to a cross connection 384. Interposed in the conduit 362 is a conventional check valve 366 which permits the flow of fluid under pressure through the valve in the direction of the arrow 388, but blocks the flow of fluid therethrough in the opposite direction. Also leading to the cross connection 384 is a direct conduit 316 from the high-pressure pump 296. Leading from the cross connection 364 is a conduit 312 for the passage of fluid under pressure to a mold-closing valve 314 and a mold-opening valve 316. Leading from the cross connection 304 is another conduit 318 for the passage of fluid under pressure to a motor valve 320. Communicating with chambers 322 and 324 in the mold-closing valve 314 are conduits 326 and 328,v respectively, which lead to the return conduit R and to a conduit 330, respectively, of which the latter is in communication with the top and bottom ends of the actuating cylinder 192 and mold cylinder 162, respectively. Conduit 312 is in permanent communication with a chamber 332' in the mold-closing valve 314. Leading fromthe chamber 332m the mold-closing valve 314 is a conduit 334 which is in communication with the mold-opening valve 316. Slidable in the chamber 332' in the valve 314 is a springurged plunger 336 which normally urges a valve element 338 into the position shown in Fig. 13 in I which it intercepts communication between the chambers 322 and 324 and provides communication between the chambers 324 and 332. Slidable inthe chamber 322 in the valve 314 is a plunger 346 which, on subjection at the rear end 342 of the valve'to fluid under pressure, will shift the valve element 338 into engagement with the valve seat 334; thereby intercepting communication between the chambers 332 and 324 and providing communication between the chambers 324 and 322.

The mold-opening. valve 316 is provided with chambers 346' and 348. The chamber 346 is in permanent communication with the conduit 334, and the chamber 348 is in permanent communication with the bottom and top ends of the actuating cylinder 192 and mold cylinder 162, respectively, through a conduit 358. Valve 316 is provided with a spring-urged plunger 352 whichnormally urges a valve element 354 into the closed position shown in Fig. 13, in which it intercepts communication between the chamber 346 and 348. Valve 316 is provided with a further chamber 356 which is in permanent communicationwith. the return :conduit R. Slidable. in the chamber'356isa plunger 358: which, onsubjeetion'at the rear end of the valve to fluid under pressure, forces a valve element 362 against a seat 364, thereby intercepting communication between the chambers 348 and 356. The valve element 362 will, on movement into engagement with its seat 364, advance a plunger 366 in the chamber 348 to a position in which the same disengages the valve element 354 from its seat 388 against the tendency of the spring-urged plunger 352 to retain it on its seat. Thus, in the respective positions of the valve elements 354 and 362 in the valve 316 shown in Fig. 13, communication between the chambers 346 and 348 is intercepted by the valve element 354, while communication between the chambers 348 and 356 is provided bythe valve element 362. Conversely, when the valve elments 362 and 354 are forced into and from engagement with their respective seats 364 and 368, communication between the chambers 346 and 348 is provided by the unseated valve element 354, while communication between the chambers 348 and 356 is intercepted by the seated valve element 362.

The motor valve 328, which is illustrated diagrammatically in Fig. 13 and in structural detail in Fig. 6, comprises a casing 318' having a chamber 312 which is closed at one end'by a plug 314, having a passage 316 with a valve seat 318. Adapted for closure on the seat 318 is a needletype valve element 388 which is axially slidable in a shell 382, threadedly received in the opposite end of the valve casing 318. The valve 388 is raised from, and lowered onto, itsseat 318 by power means described hereinafter and, when resting on its seat 318, is forced against the lat-' ter by the valve-closing pressure of a calibrated compression spring 384. The valve-closing presa sure may be regulated by adjusting the shell. 382 in the valve casing 318. The conduit 318 isin permanent communication with the passage 316 in the plug 314, and the chamber 312 is in permanent communication with a conduit 386 that leads to a solenoid valve 388. Branching from the conduit 318 is a conduit 388 which leads to h a relief or safety valve 392 (Fig. 13). The relief in the opposite direction. The chamber 396 in the relief or safety valve 392 communicates through a conduit 398 with the return conduit R. The relief or safety valve 392 serves as a bypass for fluid from the system into the return conduit R when the fluid under the previously mentioned high pressure reaches, by any accidental reason whatsoever, a predetermined safe maximum pressure. Thus, assuming that the predetermined high pressure of the fluid in the system be, way of example, 4000 pounds per square inch, as determined by the valve-closing pressure of the spring 384 in the motor valve 328, and the mentioned safe minimum pressure be 8080 pounds per square inch, the valve-closing spring 488 in the relief or safety valve 382 is accordingly calibrated to permit opening of. the valve at a pressure exceeding 800 pounds per square inch.

The solenoid valve 388 is provided with chambers 482, 484 and 488. Conduit 386 is in perma nent communication with the chamber 482 The chamber 486 is in permanent communication with the return conduit R through a conduit 488, while the chamber 484 is in permanent communication with the rear ends of the valves 314 and 316 through a conduit 418. Slidable in the chamber 486 of the solenoid valve 388 is a plunger 412,

10 having a rearwardly extending shank 414 that serves as a core for a solenoid having a winding W. A spring 416 may act on the plunger shank 414 to urge the plunger 412 into the retracted position shown in Fig. 13, in which the same permits a valve element 418 to be seated on a seat 411 to intercept communication between the chambers 484 and 486, and provide communication between the chambers 482 and 484. Conversely, on energization of the solenoid winding W, the plunger 412 is advanced into a, position in which it forces the valve element 418 into engagement with a valve seat 4128, thereby intercepting communication between the chambers 482 and 484 and providing communication between the chambers 484 and 486.

Communicating with the solenoid valve 388 through a conduit 422 is a low-pressure relief or safety valve 424 which is, in turn, in permanent communication with the return conduit R through a conduit 426. The low-pressure relief or safety valve 424 is provided for the purpose of bypassing fluid from the system directly into the return conduit R when, on the application in the system of fluid under the previously mentioned low pressure, the latter should exceed a predetermined maximum low pressure. Thus, assuming that the desired maximum low pressure of the fluid should not exceed pounds per square inch, for instance, the valve-closing spring 428 of the low-pressure relief or safety valve 424 is accordingly calibrated to permit opening of the valve under a fluid pressure in excess of 100 pounds per square inch.

It may be stated in advance that the pumps 288 and 298 are power-driven during each operating cycle of the apparatus and also between consecutive operating cycles thereof, if the controls are set for automatic repeat performance of the apparatus. Under the same control conditions of the apparatus, the motor valve 328-is open at all times, except during the application of fluid under high pressure in the apparatus, in each automatic operating cycle thereof, as will be described more fully hereinafter. Under the same control conditions of the apparatus, the solenoid winding W is de-energized at all times, except during the closure of the mold in each operating cycle of the apparatus.

Assuming now that in an automatic operating cycle of the apparatus the time has arrived for opening the mold, the motor valve 328 is then opened and the solenoid winding W ole-energized in a manner described hereinafter, while the pumps 288 and 288 keep running.

Fluid from both pumps 288 and 298 passes then through the conduits 302 and 318, respectively, to the cross connection 384, from where the fluid passes through conduit 318, motor valve 328 and conduit 386 to the chamber 482 of the solenoid valve 388. The solenoid winding W being then ole-energized, the fluid under pressure is permitted to pass from the chamber 482 to the chamber 484 in the solenoid valve 388 and through the conduit 418 to the rear ends of the valves 314 and 316. Admission of fluid under low pressure into the rear end of the valve 314 will result, as explained, in closure of the valve element 338 on its seat 344 and according interception of communi- '75 ends of the actuating cylinder 192 and mold cylinder I02, respectively, by way of the conduits 330 and 328, valve 3I4, and conduit 326 which leads to the return conduit R. Fluid under the same low pressure then also admitted into the rear end of the valve 3E0 results, as explained, in interception of communication between the chambers 348 and 353 and in the establishment of communication between the chambers 346 and 348. As soon as the valves 3M and 3I0 are shifted, as above described, by the admission of fluid under low pressure into their respective rear ends, fluid under the same low pressure also passes from the cross connection 304 through conduit 3I2, chamber 332 of valve 3I4, conduit 334, the then communicating chambers 340 and 348 of valve 3I6 and conduit 359, to the bottom and top ends of the actuating cylinder I92 and mold cylinder I02, respectively, with the result that the injection plunger I90 is returned to its most retracted or uppermost position, and the bottom mold member 86 is returned to its open position. Thereafter, and until the mold is again closed in the following operating cycle of the apparatus, the output of the pumps 288 and 290 is bypassed through the low-pressure relief or safety valve 424 and return conduit R into the reservoir 286.

To close the mold in the following operating cycle of the apparatus, the solenoid winding W is energized in a manner to be described, whereby the valve element 4I8 of the solenoid valve 388 is forced into engagement with its seat 420 (Fig. 13), blocking thereby the passage of fluid under low pressure from conduit 380 through conduit 4I0 to the valves 3I4 and H6, and instead providing for the exhaust of the rear ends of these valves by way of conduit M0, the then communicating chambers 494 and 408 in the solenoid valve 388, and the conduit 408 which leads to the return conduit R. Simultaneously with the exhaust of the rear ends of the valves 3I4 and 3I6, fluid under low pressure will pass from the cross connection 304 through the conduit 3I2, the then communicating chambers 332 and 324 of the mold-closing valve 3E4, and the conduits 328 and 330, to the top and bottom ends of the actuating cylinder I92 and mold cylinder I02, respectively, with the result that the injection plunger I90 will be forced through the greater part of its injection stroke without forcing molten plastic from the discharge nozzle 62, and the bottom mold member 86 will be raised into closing relation with the top mold member 54. Simultaneously with the admission of fluid under low pressure into the top and bottom ends of the cylinders I92 and 502, respectively, their opposite ends are permitted to exhaust by way of the conduit 350, valve 3 I 6 and return conduit R.

Immediately on closure of the mold 54, 86 in each operating cycle of the apparatus, the motor valve 320 is closed as more fully described hereinafter, interrupting thereby the flow of fluid through the motor valve. With the solenoid winding W still energized, the bottom and top ends of the cylinders I92 and I02 remain in exhaust communication with the return conduit R. Closure of the motor valve 320 then leaves, for the sole immediate passage of fluid under pressure from the cross connection 304, the conduit 3I2, the communicating chambers 332 and 324 of the mold-closing valve 3I4, the conduits 328 and 330, and the top and bottom ends of the cylinders I92 and I02, respectively, with the result that the output of the high pressure pump 290 will soon increase the pressure of the fluid in the system to the mentioned high pressure which holds the mold 54, 06 safely closed and imparts to the injection plunger I its final movement to the end of its injection stroke during which it will force a molten plastic charge from the discharge nozzle 62 into the closed mold. When the injection plunger I90 reaches its lowermost position, the output of the high pressure pump 290 is balanced by the valve-closing pressure of the valve element 390, and the pressure in the system reaches a constant predetermined value. While the fluid in the system is under high pressure, fluid from the low pressure pump 288 is obviously under insufficient pressure to open the check valve 306 and pass into the system, instead the fluid under low pressure will pass through the medium-pressure valve 294 into the return conduit R. Fluid under high pressure is retained in the system for a predetermined time period during which the injected plastic charge in the closed mold will be permitted to solidify to an extent where the molded product may, on subsequent opening of the mold, be safely removed therefrom. The time period during which the fluid in the system is under high pressure is governed by certain controls described hereinafter.

At the end of the referred high pressure time interval in each operating cycle of the apparatus, opening of the motor valve 320 relieves immediately the high pressure through conduit 396 and low pressure relief or safety valve 424. As soon as the motor valve 320 is completely opened, the solenoid winding W is de-energized, as more fully described hereinafter. De-energization of the solenoid accordingly results in immediate admission of fluid under low pressure through conduit 386, the then communicating chambers 402 and 404 of the solenoid valve 388 and the conduit 4 IE), to the rear ends of the valves 3I4 and 3I6, permitting thereby the exhaust of the top and bottom ends of the cylinders I92 and I02,- respectively, by way of the conduits 330 and 328, the then communicating chambers 324 and 322 in the mold-closing valve 3| 4, and the conduit 326 which is in permanent communication with the return conduit R. Simultaneously with the exhaust of the top and bottom ends of the cylinders I92 and I02, respectively, fluid under low pressure from both pumps 288 and 290 is also admitted to the bottom and top ends of the same cylinders I92 and I02, respectively, by way of the cross connection 304, conduit 3I2, chamber 332 in valve 3I4, conduit 334, the then communicatingchamhers 346 and 348 in valve 3I6, and the conduit 350, with the result that the mold 54, 86 will be opened and the injection plunger I90 will be retracted to its uppermost position. Unless the apparatus is then stopped at the end of the present operating cycle, either by manual or automatic controls to be described, the pumps 288 and 290 will continue to operate and their output will be by-passed through the low-pressure relief or safety valve 424 into the return conduit R, until the mold 54, 86 is again closed in the next operating cycle of the apparatus.

Reference is now had to Figs. 1, 2, 6, 7 and 8, which show the power means for opening and closing the motor valve 320. This means comprises a valve motor 440 to the shaft 442 of which is coupled at 444 a pinion 446 that is in permanent mesh with a gear disk 448, threaded with its hub 45!] over a spindle-like extension of the valve element 380 in the motor valve 320. The motor 440 may suitably be mounted on the top frame 24 of the apparatus, and the motor valve 328 may, through intermediation ofa bracket 454, be suitably secured to a mounted panel 456 on the top frame 24 and upper platen 28. The gear disk 448 normally rests, in the open position of the motor valve 328 (Fig. 6), on a thrust bearing 458 on the bracket 454. The valve element 386 of the motor valve 328 is held against rotation in either direction by an arm 466 which may be clamped or otherwise secured at 462 to the valve element 388, and a metal strap 464 on the panel 456 which confines the arm 468 into close proximity to the panel, yet permit movement of the arm 468 with the valve element 388 into the open and closed positions of the latter. The valve motor 448 is of the reversible type, and its circuit for causing closure of the motor valve 320 is closed, as hereinafter described, at the proper time in each operating cycle of the apparatus when fluid under high pressure is to be applied to the hydraulic system thereof. When the valve motor 448 i thus operated, the non-rotatable valve element 588. will; by virtue of its threaded engagement with the gear disk 448, be lowered into engagement with its seat 318 (Fig. 7), whereupon continued operation of the motor 448 in the same direction will cause the gear disk 448 to climb on the valve element 388 until it actuates an overrun switch 418 (Fig. 8). Actuation of the switch 418 by the gear disk 448 will, as hereinafter described, effect closure of a reverse circuit of the valve motor 448 for reverse operation of the same. The gear disk 448 will then be driven from the motor 448 in the opposite direction in which to descend on the closed valve element 388 until it becomes reseated on the thrust, bearing 458. Thereupon, and during continued operation of the valve motor 448 in reverse direction, the gear disk 448 will retract the valve element 386 into its open position (Fig. 6). On return of the valve element 388 to its open position, it will actuate a motor limit and solenoid switch 412 which, on such actuation, will open the mentioned reverse circuit of the valve motor 449, whereupon the latter will come to a stop with the parts 388 and 448 in the position shown in Fig. 6. The switch 412 is suitably mounted on the outer surface of the panel 456, while the switch 418 is carried by an arm 488 which is pivotally mounted on the opposite surface of the panel 456 (Fig. 1). The arm 488 may rest against a set screw 482 in a block 484 on the panel 456. The set screw 482 serves to adjust the vertical position of the switch 478 on the arm 488, to thereby vary the time period in each operating cycle of the apparatus during-which the mold 54, 86 is held closed by fluid under high pressure. In order that the gear disk 448 may actuate the switch 418, as described, the former extends through an opening 488 in the panel 456.

The ejector arm 248 is swung into its in and out positions by an arm motor 498 (Figs. 1 and 3), having suitably coupled to its shaft a pinion 492 which is in permanent mesh with a gear 494, having a coaxially extending pinion 466 that is in permanent mesh with another gear 468, mounted on the spindle 242. The spindle 242 is driven at a speed which is considerably reduced from that of the motor 498 by means of a pre-loaded compression spring 588 which acts on the spindle 242 as a clutch, thus enabling the ejector arm 246 to be moved by hand, if necessary, when adjusting its level. The motor 498 may suitably be mounted on a plate 582 (Fig. 3) which, in turn, is mounted at 584 on the top frame 24 of the apparatus, The gear 494 and pinion 496 may suitably be journalled in a bracket arm 586, clamped to, or otherwise mounted on, one of the posts 26.

As best shown in Figs. 1 and 2, there are -mounted on the top frame 24 of the apparatus 7 two spaced bracket arms 518 to the forward ends of which is suitably secured, as at 512, a rod Hinged at l6 to the rod SM is a guard 5|8 of any suitable transparent, preferably plastic, material. The guard 518, which may be swung into the raised position shown in Figs.

1 and 3, is normally swung into the dot-anddash line position shown in Fig. 2 in which it extends substantially to the level of the stationary top mold member 54 in order to protect an I operator from flying plastic which, due to overheating or for some other reason, may be blown from the closed mold or along the injection plunger I98. The swingable guard 5l8 performs the further function of permitting operation of .the apparatus only when it assumes the protective dot-and-dash line position shown in Fig. 2.

- To this end, there is suitably mounted on the rod 5E4 a guard switch 528 which, as hereinafter :described, permits operation of the apparatus 2 only when actuated by the guard 5l8 in its pro- Included among the electrical operating and control devices of the apparatus are several other prominent switches which will be referred to presently. Thus, mounted on the upper platen :28 in any suitable manner is a normally open -mold switch 538 (Figs. 1 and 2), which is closed, when the mold 54, 86 is closed, by means I of an adjustable screw 532 on a bar 534, ad-

sjustably mounted at 535 on the lower platen 38.

Suitably mounted on the ejector arm 248 is a normally open sprue switch 536 which is closed when the sprue s of a molded product p is gripped between the jaws 248 on the ejector arm 246 (Fig. 11).

To this end, the actuating arm 538 of the switch 536 is connected by a link 548 with an arm 542 which is pivoted at 544 on one 0f the jaws.248 (Fig. 10).

When the ejector arm 248 is swung from its out position inwardly between the partially open mold 54, 86 for gripping the sprue s of a molded product between the jaws 248, as hereinbefore described,

the arm 542 is turned by the sprue s into the position shown in Fig. 11, in which the switch 536 is closed through intermediation of the link The switch 536 remains closed until the sprue s is released from the jaws 248, as will be readily understood.

Suitably mounted on brackets 548 and 558 on -the base frame 22 of the apparatus are switches 552 and 554, respectively, hereinafter referred to as mold-in and mold-out switches, respectively (Fig. 3).

Mounted at 556 on the lower platen 30 is a bracket 558, carryin spindles 568 .and 562 which are threadedly received by blocks 564 and 566, respectively, that are slidable on the bracket 558 and thereby prevented from turning relative to their respective spindles 568, 562. The block 564 suitably carries a cam-like element 568 which is adapted to actuate the switch 552 when the bottom mold member 86 is substantially retracted from the top mold member 54, but is still above its lowermost p0- 15 sition. The block 566 is adapted to actuate the switch 554 when the bottom mold member 86 is in its lowermost position.

Suitably mounted on the upper platen 28 of the apparatus are two switches 516 and '12 (Figs. 1 to '3), hereinafter referred to as arm-in and arm-out switches respectively. These switches 510 and 512 are actuated by cams 514 and 516, respectively, on the spindle 242.

Suitably mounted on the brackets 580 and 582, which suitably depend from the top frame 24 of the apparatus, are a plunger switch 584 and a feed switch 566, respectively, both of which are actuated by the injection plunger I90 in a manner hereinafter described.

Reference is now had to the wiring diagram in Figs. 14 and 15 in which the electrical operating and control devices of the apparatus and their connections are diagrammatically illustrated. Shown in the wiring diagram are several control switches not heretofore mentioned. Thus, there are provided a stop switch 590 of the push button type, a settable cyclealarm switch 592, a start switch 594 of the push button type, a settable run-jog switch 596, a settable arm switch 598, an up switch 600 of the push button type, a down switch 602 of the push button type, a settable pressure switch 604, an initial-heating switch 606 of the push button type, a settable heat-control switch 608, a settable feeding switch 6l0, a manual-feed switch 6l2 of the push button type, and a shoot switch GM of the push button type. The apparatus is further provided with a normally closed thermo switch 6l6, preferably of the bi-metallic type, which may be mounted at any convenient place (not shown) on the 'top mold member 54 where it is in close proximity to the heating chamber I98 in the injection cylinder '64 and subjected to the heat therein. The thermo switch 616 will open when the temperature of the molten plastic in the discharge nozzle 62 will exceed a predetermined maximum temperature. The main switch of the apparatus is indicated in the wiring diagram by the reference numeral (H8. The main switch M8 is normally open, and is closed bya main-switch re1ay'620.

In order to start the apparatus from a cold state, i. e., after prolonged idleness of the same during which the heater elements 204 and 206 were de-energized, the operator will set the runjog switch 596 to run position in which the contacts A2, (42 and B2, b2 are bridged as indicated by dotted lines in the wiring diagram. The

operator then momentarily depresses the start switch 5534, thereby bridging the contacts 624 and 626 thereof and consequently closing a starting circuit of the main switch relay 620. This circuit comprises one side LI of a power line, leads 626 and 630, the momentarily bridged contacts 624 and .626 of the start switch 594, a lead 632, relay 620, a lead 034, the normally closed stop switch 590, a lead 636, a normally closed alarm switch 638 and the other side L2 of the power line. Energization of the main switch relay 620, in consequence of the momentary closure of the described starting circuit thereof, results in closure of the auxiliary switches 640, 642, 644 and 646 of the main switch 6I8. One phase of a three-phase current source is permanently conneoted by a lead 648 with a pump motor (not shown) which drives the pumps 288 and 290. Closure of the auxiliary switches 640 and 642 reother ,phases of the three-phase current source with the pump motor, causing thereby operation of the latter. Closure'of the auxiliary switch 644 results in connection of the permanently available side Ll' of the power line with a number of terminals Ll in the apparatus, the terminal Ll nearest the auxiliary switch 644 being accordingly connected with all other terminals Ll by leads (not shown). Closure of the auxiliary switch 646, also in consequence of momentary closure of the described starting circuit of the main switch relay 620, results in closure of a holding circuit of the latter relay. This holding circuit comprises the side LI of the power line, leads 654 and 056, the auxiliary switch 646, a lead 658, the bridged contacts A2, a2 of the run-jog switch 596, leads 660 and 662, the guard switch 520 (which is closed when guard 5|8 is lowered), a lead 664, the lead 632, relay 620, lead 634, the normally closed stop switch 590, lead 636, the normally closed alarm switch 639, and the other side L2 of the power line.

The operator may next set the heat-control switch 608 to automatic position in which the contacts .A-2, a2 and BI, bl are bridged as indicated in dotted lines in the wiring diagram (Fig. 14). All terminals Ll having previously been connected with the side Ll of the power line, the circuits of the heater elements 204 and 206 will be closed immediately on setting the heat-control" switch 608, as described. These circuits have a rump portion, comprising a terminal Li, leads 666 and 668, the bridged contact Bl, bl of the heat-control switch 608, a lead 610, the then closed thermo switch H6, and a lead 612 from which branch the heater elements 204 and 206, the latter being connected with the side L2 of the powerline. In series connection with the heater element 206 is a variable resistance 674 wherewith to regulate the heat output of the heater element 206. Since the injection plunger l 00 is normally in its uppermost position when the apparatus is idle, and the feed screw 2|4 (Fig. 3A) feeds plastic only when the injection plunger I90 is in its lowermost position in each operating cycle of the apparatus, it stands to reason that normally there is plastic material present in the heating chamber I98 in the injection plunger 64 at the time of a cold start of the apparatus. This plastic will be heated in the chamber i-68 by the surrounding heater elements 204 and 206 until it becomes molten and acquires proper molding temperature. This requires some time after the heat-control switch 608 has been set, as described.

The operator is not compelled to await the melting of the plastic in the injection cylinder 64 before conditioning the apparatus for automatic repeat molding-cycle performance, for instance,

but may do so at any time after setting the heat- :contrOl switch 608, as described. To this end, the

operator may set the cycle-alarm, arm, pressure, and 'feeding switches 592, 598, 604 and H0, respectively, so that the contacts A2, a2 and BI, bl of switch 592, the contacts A2, a2 and B2, b2 of switch 598, the contacts A2, a2 and B2, b2 of switch 604, and the contacts A, a of switch 6|0, are bridged as indicated by dotted lines in the wiring diagram. However, the conditioning of the apparatus for automatic repeat molding-cycle performance is not completed with the described setting of the switches 592, 598, 604 and 6l0, but additionally requires momentary depression by the operator of the initial-heating switch 606 .sults in connection by leads 650 and 652, of the for momentary connection of the contacts A and 

